Valve assembly for inflatable bladder and method of manufacturing the same

ABSTRACT

The present invention relates to inflatable bodies or systems with bounding walls or bladder structures and at least one valve assembly thermally bonded thereto. More particularly, the present invention provides a valve assembly for inflatable bodies typically made from a thermoplastic rubber material or the like, which will exhibit significantly increased strength and durability during inflation and while inflated, especially at and around the interface between the air valve assembly and the bounding wall of the inflatable body because of the enhanced strength of the interface through thermal sealing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application relates to, and claims priority as a divisionalapplication from, U.S. Ser. No. 14/416,089 filed Jan. 21, 2015, theentire contents of which are incorporated herein by reference, which inturn claims priority from SN. PCT/US2014/017819 filed Feb. 21, 2014, theentire contents of which are incorporated herein by reference, which inturn claims priority to U.S. Prov. Ser. No. 61/768,280 filed Feb. 22,2013.

FIGURE SELECTED FOR PUBLICATION

FIG. 9.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to inflatable bodies or systems withbounding walls or bladder structures and at least one valve assembly.More particularly, the present invention provides a valve assembly forinflatable bodies typically made from thermoplastic rubber material andthe like which will exhibit significantly increased strength anddurability during inflation and while inflated especially at and aroundthe interface between the air valve assembly and the bounding wall ofthe inflatable body.

Description of the Related Art

The prior art is directed to methods and apparatus for flexible airvalves for use in inflatable bodies including, for example, balloons,sports balls, toys, exercise balls or equipment, inflatable boats,inflatable castles or other structures, and the like. Such inflatableproducts are typically fashioned from flexible polymer materials. As thestrength of flexible polymer materials has improved over the years,inflatable product sizes have also increased. Inflatable items havingsmall diameters have grown to large diameter inflatable structures orbodies.

The insertion of air into the inflatable body is typically accomplishedby the use of a manual or electric air pump. The air pressure generatedby the air pump is delivered to the inflatable body via an air hose. Theair pump hose typically has a diameter larger than the inside diameterdimension of the opening of the air valve fitted in the inflatable body.In order to interface the hose from the air pump to the inflation airvalve, a needle or other adapter or reducer is typically employed. Sucha needle or other adapter or reducer is normally fitted on the end ofthe air hose and used for all inflatable bodies. The needle/adapterenables a standard size air hose extending from the air pump to beforce-fitted into the air valve for filling the inflatable body withair.

However, the effectiveness of the air pump in delivering air to theinflatable body is controlled by the inside diameter dimension of theopening of the air valve fitted within the inflatable body. Generally,the larger the inside diameter dimension of the inflation air valve, thegreater the effectiveness of the pump in inflating the body.Unfortunately, the inside diameter dimension of the air valves known inthe prior art is small. While an air valve having a larger diameter anda greater cross-sectional area would result in increased effectivenessof the inflation air pump, several reasons exist for the absence ofinflation air valves having a larger diameter and a greatercross-sectional area.

Various kinds of typical air valve and air valve assemblies have beendeveloped for inflating air bladders, balloons, sports balls, or thelike, and generally comprise a plug made of compressible material andhaving a needle passageway arranged for allowing a needle to passthrough it and to expand towards itself to completely close when theneedle is removed from the plug, and to ensure that pressurized airwithin the bladder cannot escape through the air valve.

For example, one such air valve is disclosed for use in a sportsballsuch as a soccer ball or volleyball to provide good air retention anddurability. Such a valve, however, is preferably permanently sealed tothe particular bladder, and is formed from a thermoplastic polyurethaneelastomer similar to that used in the inner core. The air valve has acylindrical-shaped body with a sealing flange, an air passage neck and asnap-in retaining flange. The body of the valve has a chamber within itscentral area in which a rubber pellet is placed to seal the interior ofthe bladder from the atmosphere and prevent the air used for inflationof the ball from escaping. The polyurethane valve is preferred due tothe fact it will permanently bond with the wall of the inner core toensure its full retention without an air leaking problem. Optimumbonding results from an inner core and an air valve made of the samethermoplastic material. However, the plug which is made of compressiblematerial may fail after use. In addition, the air valve has noprotective structure to absorb a force from the inflating needle.

Another known air valve for use in an inflatable bladder guards againstaccidental puncturing of the bladder by an inflating needle. The airvalve includes a main body member with a core which has a neck at oneend and an inflating needle passageway with a chamber extending throughit. The air valve also includes an air sealing plug for positioning inthe chamber and a protective bonnet positioned on a second end of themain body member. The main body member has an annular sealing flangeextending radially from the first end and a snap-in retaining flangeextending radially from the neck such that a bladder and an outer casingare trapped between the two flanges in a sealing relationship. Theprotective bonnet has at least one air escape opening to allowpressurized air from the inflating needle to pass into the bladder. Inother words, the air valve has a protective bonnet permanentlypositioned within the bladder or the sports ball, and made of a rigid orsemi-rigid plastic material to absorb the force from the inflatingneedle. However, the protective bonnet is spaced away from the needlepassageway of the plug, and may not be used to block the needlepassageway of the plug when the plug has become failure after use.

Bladders or bounding walls of inflatable bodies are conventionally madeof rubber, latex, nylon, vinyl, polychloroprene, synthetic fabric,synthetic rubber, natural rubber, and the like. Other flexible materialsfor use in inflatable bodies include thermoplastic elastomers (TPE),otherwise known as thermoplastic rubbers (TPR), which are a class ofcopolymers or a physical mix of polymers (usually a plastic and arubber) consisting of materials with both thermoplastic and elastomericproperties. While most elastomers are thermosets, thermoplastics are incontrast relatively easy to use in manufacturing, for example, byinjection molding. Thermoplastic elastomers show advantages typical ofboth rubbery materials and plastic materials. The principal differencebetween thermoset elastomers and thermoplastic elastomers is the type ofcrosslinking bond in their structures. In fact, crosslinking is acritical structural factor which contributes to impart high elasticproperties. The crosslink in thermoset polymers is a covalent bondcreated during the vulcanization process. On the other hand, thecrosslink in thermoplastic elastomer polymers is a weaker dipole orhydrogen bond or takes place in one of the phases of the material.

There are six generic classes of commercial TPEs/TPRs: Styrenic blockcopolymers; Polyolefin blends; Elastomeric alloys (TPE-v or TPV);Thermoplastic polyurethanes; Thermoplastic copolyester; andThermoplastic polyamides. Examples of TPE/TPR products that come fromblock copolymers group are Arnitel (DSM), Engage (Dow Chemical), Hytrel(Du Pont), Dryflex and Mediprene (ELASTO), Kraton (Shell chemicaldivision), and Dynalloy (Polyone Corporation). In order to qualify as athermoplastic elastomer, a material must have the following threeessential characteristics: (i) demonstrate the ability to be stretchedto moderate elongations and, upon the removal of stress, return tosomething close to its original shape; (ii) be processable as a melt atelevated temperature; and (iii) exhibit the absence of significantcreep. Some of the properties of TPE/TPR materials generally include:light weight; colorability; high tear strength; excellent abrasionresistance; excellent dimension stability; low temperature flexible;excellent weather resistance; performance like vulcanized rubber;reusable and recyclable; non-migratory; and excellent electricalproperties.

Advantageously, TPE/TPR materials have the potential to be recyclablesince they can be molded, extruded and reused like plastics, but theyhave typical elastic properties of rubbers which are not recyclableowing to their thermosetting characteristics. TPE/TPR materials alsorequire little or no compounding, with no need to add reinforcingagents, stabilizers or cure systems. Therefore, batch-to-batchvariations in weighting and metering components are absent, leading toimproved consistency in both raw materials and fabricated articles.TPEs/TPRs can be easily colored by most types of dyes. In addition,TPEs/TPRs consume less energy and allow closer and more economicalcontrol of product quality during manufacture.

On the other hand, TPEs/TPRs, relative to conventional rubber orthermoset, require relatively more expensive raw materials, aregenerally unable to be loaded with low cost fillers, such as carbonblack (therefore preventing TPEs from being used in automobile tires),have poor chemical and heat resistance, and have high compression setand low thermal stability. Also, TPEs/TPRs may soften or melt atelevated temperatures above which they lose their rubbery behaviour.

The two most important manufacturing methods with TPEs/TPRs areextrusion and injection molding. Compression molding is seldom, if ever,used. Fabrication via injection molding is extremely rapid and highlyeconomical. Both the equipment and methods normally used for theextrusion or injection molding of a conventional thermoplastic aregenerally suitable for TPEs/TPRs. TPEs/TPRs can also be processed byblow molding, thermoforming, and heat welding.

TPEs/TPRs may be used where conventional elastomers cannot provide therange of physical properties needed in the product. These materials findlarge application in the automotive sector and in household appliancessector. Thus, co-polyester TPEs/TPRs are used in snowmobile tracks wherestiffness and abrasion resistance is at a premium. They are also widelyused for catheters where nylon block copolymers offer a range ofsoftness ideal for patients. Thermoplastic silicon and olefin blends areused for extrusion of glass run and dynamic weatherstripping carprofiles. Styrene block copolymers are used in shoe soles for their easeof processing, and widely as adhesives. TPEs/TPRs are commonly used tomake suspension bushings for automotive performance applications becauseof its greater resistance to deformation when compared to regular rubberbushings. TPEs/TPRs may also be used in products meant for bodilyinsertion, and are also finding more and more use as electrical cablejacket/inner insulation.

Other applications of TPEs/TPRs include the footwear industry (forexample, in the production of shoes soles, loafers sole, safety shoessole & industrial shoes sole, sports shoes sole, ski-boot soles, kiddyshoes sole and related decorative accessories, unisole, modifierasphalt, modification modifier for SMC (sheet moulding compound) andother thermoset & thermoplastic composites), the automotive, sports andleisure industries (for example, in profiles, gaskets, lip-seals,tubings, pipes, co-extrusion automotive gasket, o-ring, bushings,bellows, floor mat, protecting covers, automotive grip, food & medical,ball pen grip, tooth brush grip, umbrella handle grip, milk tubing,disposable medical product, beverages), and the electrical andelectronics industry (for example, in manufacturing welding cable,jacketing, flexible cord, primary wire, fire retardant control cable).

Synoprene Polymers Pvt. Ltd., one manufacturer of TPE/TPR materials,offers quality thermoplastic rubber, which is a part of StyreneElastomer family that displays rubber like properties having styrenicbased segment to achieve excellent strength. Besides conventionalvulcanized rubber, it delivers superior properties to make replacementapplication of rubber and soft plastic in the sense of processing andend uses. Our compounding ability makes TPR as a homogeneous compositionto achieve excellent quality and processability. This Synoprene® TPR isbased on styrenic as hard segment & soft phase consists of rubberybutadiene center and crystalline styrene at ends. It can combine wellwith many other elastomers, extenders, modifiers and other resins. Allthese combinations can be controlled to vary properties such as tackstiffness, softening temperatures and cohesive strengths according tothe needs of specific and general usage. It is being widely accepted dueto its various range in cost effective and value engineered concepts.

The present invention recognizes the need for an improved air valveassembly for highly durable inflatable bodies typically made fromTPE/TPR material and the like which will exhibit significantly increasedstrength and durability during and after inflation, especially at andaround the interface between the air valve assembly and the boundingwall of the inflatable body. The present invention has arisen tomitigate and/or obviate the aforementioned disadvantages of theconventional air valves.

SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide an improvedair valve assembly for inflatable bodies typically made fromthermoplastic rubber material and the like which will exhibitsignificantly increased strength and durability during inflation andwhile inflated, especially at and around the interface between the airvalve assembly and the bounding wall of the inflatable body.

In accordance with one aspect of the invention, there is provided an airvalve assembly for attachment to an inflatable thermoplastic rubberbladder or bounding wall structure, the air valve assembly comprising avalve member having a flange extending radially therefrom, the valvemember including a bore formed therein and a slot valve extendingtherefrom with a central opening communicating with the bore of thevalve member. The opening of the slot valve has an inner diameter suchthat air may not flow in a reverse direction therethrough. The valvemember further comprises an integrally bonded o-ring around the bore ofthe valve member, the o-ring providing added strength and durabilityduring and after inflation of the inflatable bladder or bounding wall.The valve member including a peripheral sealing flange extended radiallytherefrom for attaching to the bladder or bounding wall.

The above and other aspects, features and advantages of the presentinvention will become apparent from the following description read inconjunction with the accompanying drawings, in which like referencenumerals designate the same elements.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the present invention can be obtained byreference to a preferred embodiment set forth in the illustrations ofthe accompanying drawings. Although the illustrated preferred embodimentis merely exemplary of methods, structures and compositions for carryingout the present invention, both the organization and method of theinvention, in general, together with further objectives and advantagesthereof, may be more easily understood by reference to the drawings andthe following description. The drawings are not intended to limit thescope of this invention, which is set forth with particularity in theclaims as appended or as subsequently amended, but merely to clarify andexemplify the invention.

For a more complete understanding of the present invention, reference isnow made to the various following drawings in which:

FIG. 1 shows a top perspective view of one alternative air valveassembly integrated with an inflatable bladder member in accordance witha first embodiment of the invention;

FIG. 2 shows a partial top cutaway perspective plan view of a portionthe inflatable bladder shown in FIG. 1 showing the slot valve of the airvalve assembly according to the first embodiment of the invention;

FIG. 3 shows a cross sectional view of the valve assembly of theinvention taken at line 3-3 of FIG. 2, illustrating the inner details ofthe air valve assembly according to the first embodiment of theinvention, and further illustrating the insertion of a pump needle forinflation of the inflatable bladder;

FIG. 4 shows a partial top cutaway perspective plan view of a portionthe inflatable bladder shown in FIG. 1 showing the slot valve of the airvalve assembly according to the first embodiment of the invention,further illustrating the insertion of a pump needle and the flow of airthrough the slot valve of the air valve assembly into the inflatablebladder;

FIG. 5 shows a cross sectional view of the valve assembly of theinvention taken at line 5-5 of FIG. 4, illustrating the inner details ofthe air valve assembly according to the first embodiment of theinvention with the pump needle inserted into the air valve assembly forinflation of the inflatable bladder;

FIG. 6 shows a top perspective view of a further alternative air valveassembly integrated with an inflatable bladder member in accordance withan alternative second embodiment of the invention;

FIG. 7 shows a partially exploded top perspective view of the air valveassembly and inflatable bladder member in accordance with the secondembodiment of the invention;

FIG. 8 shows a partial top cutaway perspective view of a portion theinflatable bladder shown in FIGS. 6-7 showing the opening of the airvalve assembly according to the invention, further illustrating thedirection of insertion of a pump needle or inflator into the air valveassembly;

FIG. 9 shows a cross sectional view of the valve assembly of theinvention taken at line 9-9 of FIG. 8, illustrating the inner details ofthe air valve assembly according to the second embodiment of theinvention;

FIG. 9A shows a cross sectional view of the valve assembly of theinvention taken at line 9-9 of FIG. 8, illustrating the inner details ofan alternative embodiment of the air valve assembly according to thesecond embodiment of the invention;

FIG. 9B shows a cross sectional view of the valve assembly of theinvention taken at line 9-9 of FIG. 8, illustrating the inner details ofa yet another alternative embodiment of the air valve assembly accordingto the second embodiment of the invention, and it will be recognizedthat alternative valve assembly shapes and constructions can existwithout departing from the scope and spirit of the present invention;

FIG. 10A shows a partial cross sectional view of the valve assembly ofFIGS. 9-9A, showing the valve of the air valve assembly according to thesecond embodiment of the invention, further illustrating the insertionof a pump needle or inflator and the beginning of the flow of air fromthe inflator into an inner region of the valve assembly and into theinflatable bladder;

FIG. 10B shows a partial cross sectional view of the valve assembly ofFIGS. 9-9A, showing the valve of the air valve assembly according to thesecond embodiment of the invention, further illustrating the flow of airfrom the inflator into an inner region of the valve assembly and througha second valve opening into the inflatable bladder;

FIG. 10C shows a partial cross sectional view of the valve assembly ofFIGS. 9-9A, showing the valve of the air valve assembly according to thesecond embodiment of the invention, further illustrating the resealingof the valve openings upon removal of the pump needle or inflator afterthe inflation of the inflatable bladder;

FIG. 11A shows a first step in the method of securing the valve assemblyto the inflatable bladder or body using a thermal sealing technique inaccordance with an embodiment of the present invention, in particularshowing the flange region of the valve member being wrapped around anend of a cylindrical heating rod; and

FIG. 11B shows a second step in the method of securing the valveassembly to the inflatable bladder or body using a thermal sealingtechnique in accordance with an embodiment of the present invention, inparticular showing the valve member being inserted into a boundedopening in the inflatable body which is then secured with a sealingcollar to firmly hold the bounded wall of the inflatable body againstthe flange region of the valve member during the thermal sealing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As required, a detailed illustrative embodiment of the present inventionis disclosed herein. However, techniques, systems, compositions andoperating structures in accordance with the present invention may beembodied in a wide variety of sizes, shapes, forms and modes, some ofwhich may be quite different from those in the disclosed embodiment.Consequently, the specific structural and functional details disclosedherein are merely representative, yet in that regard, they are deemed toafford the best embodiment for purposes of disclosure and to provide abasis for the claims herein which define the scope of the presentinvention.

Reference will now be made in detail to several embodiments of theinvention that are illustrated in the accompanying drawings. Whereverpossible, same or similar reference numerals are used in the drawingsand the description to refer to the same or like parts or steps. Thedrawings are in simplified form and are not to precise scale. Forpurposes of convenience and clarity only, directional terms, such astop, bottom, up, down, over, above, below, etc., or motional terms, suchas forward, back, sideways, transverse, etc. may be used with respect tothe drawings. These and similar directional terms should not beconstrued to limit the scope of the invention in any manner.

Referring first to FIGS. 1-2, respectively, shown are a top perspectiveview of a air valve assembly 14 integrated with an inflatable bladder 10having an inner surface 24, and a partial top cutaway perspective planview of a portion the volume or inflatable bladder 10 shown in FIG. 1showing the slot valve 20 of the air valve assembly 14 according to apreferred embodiment of the invention. As will be described in moredetail below, the present invention provides a valve assembly 14 forinflatable bodies 10 typically made from thermoplastic rubber materialand the like which will exhibit significantly increased strength anddurability during inflation and while inflated, especially at and aroundthe interface between the air valve assembly 14 and the bounding wall 16of the inflatable body 10. The air valve assembly 14 in accordance withthe present invention comprises a valve body or air valve member 18including a peripheral sealing flange 12 extended radially therefrom,such as the upper end thereof, for attaching to the inner or outerportion of bladder or bounding wall 16 of an inflatable body 10.

The bounding wall or bladder 16 of the inflatable body 10 may be madefrom thermoplastic polyurethane elastomer (TPE) materials orthermoplastic rubber (TPR) materials, such as polyester-based orpolyether-based polyurethane, polyvinyls, polyesters and polyethers,etc., which contribute a desired property, e.g. air retention, abrasionresistance, etc. Kraton is one such preferred material for use as thebladder or bounding wall 16 of the inflatable body in accordance withthe present invention. Other high-expansion materials may be employedwithout departing from the scope and spirit of the present invention.These materials may be mixed with colorants or fillers to adjust color(e.g., to make a big character figure (Sponge Bob®) or colored like a‘Super-Man’ cape) also without departing from the scope and spirit ofthe present invention.

As shown in FIGS. 3-5, shown is the valve member 18 of the inventionillustrating the inner details of the air valve member 18 according to apreferred embodiment of the invention, and further illustrating theinsertion of a pump needle 26 for inflation of the inflatable bladder orbounding wall 16. As shown, the air valve member 18 includes a centralbore 34 formed therein. The valve member 18 also includes a slot valve20 extending therefrom with a central opening 22 communicating with thebore 34 of the valve member 18. The opening 22 of the slot valve 20 hasan inner diameter such that air may not flow in a reverse directiontherethrough (i.e., the internal air pressure effectively closes theslot valve opening 20 (by pressing the opposing sides of the slot valvetogether, see arrows P-P in FIG. 2) when air is not being forced throughit into the inflatable body 10. The valve member 18 further comprises anintegrally bonded (or co-bonded) o-ring 32 around the bore 34 of thevalve member 18. The o-ring 32 provides added strength and durability tothe valve member 18 during and after inflation of the inflatable bladderor bounding wall 16. Optimally, such improvement is on the order of1000-8000 times on the stress strength and/or durability of thevalve/bounding wall interface. As this causes substantial volumetricexpansion stress at the valve site (which itself cannot expand)selection of proper materials is essential to suitable function.

It is preferable that the valve member 18 and the o-ring 32 be of thesame TPR material as well as the bounding wall or bladder 16, but thatthe o-ring 32 be of a higher density than the material of the valvemember 18. Providing such integrally bonded or co-banded, higher densityo-ring 32 within valve member 18 will provide the added strength anddurability to the valve/bounding wall interface. Thus, importantfeatures include: a higher density o-ring 32, co-bonding of the o-ring32 with valve member 18, and use of the same material for o-ring 32 andbounding wall 16. Also, it is preferred that angled tip be used on valveor pump coupling 26 to assist in making sure that consistent air flow ispossible during filling. Further, a bulge 28 on the filler neck of valveor pump coupling 26 “pops” past insert molded o-ring 32 in the valvemember 18, as seen in FIG. 5, to securely seat valve or pump coupling 26into valve member 18 for inflation of the inflatable body 10. As can beseen in FIG. 4, during inflation, central opening 22 of slot valve 20expands to allow greater flow of air into the interior of bounding wallor bladder 16 of inflatable body 10. Once inflation stops, the internalair pressure is great enough to hold central opening 22 of slot valve 20closed such that air may not escape from the inflated body 10.

In operation, the valve or pump coupling 26 is engageable through thecentral bore 34 of the valve member 14 for inflating the bladder 16.After the bladder 16 has been inflated and when the valve or pumpcoupling 26 has been disengaged from the central bore 34, thepressurized air in the bladder 16 may force the central opening 22 ofthe slot valve 20 to close and thus to block passage of any air frominside bladder 16 to the exterior. Accordingly, the air valve member 18in accordance with the present invention includes a structure, or slotvalve 20, configured such that the air passage will be substantially, ifnot completely, blocked upon removal of the needle or pump valve 26 fromthe air valve member 18, and to ensure that pressurized air within thebladder or bounding wall 16 cannot escape through the air valve member18. In other words, slot valve 20 functions as a one-way valve.Preferably, valve member 18 is formed using injection molding, althoughother known techniques may be employed.

Referring next to FIGS. 6-9A, shown is a top perspective view of analternative air valve assembly integrated 60 with an inflatable bladdermember in accordance with a second alternative embodiment of theinvention. As seen in FIG. 6, the valve 60 according to a preferredembodiment of the invention is for use with an inflatable bladder orvolume 50. In this embodiment, valve 60 preferably has a generallycircular configuration for insertion into a correspondingly circularopening 51 in the inflatable bladder or volume 50. As discuss herein,valve 60 is preferably thermally sealed within opening 51 in the volumeor inflatable bladder 50. Valve 60 is preferably configured with agenerally flat outer surface with a valve entry hole 67 positioned inthe central region thereof for receiving an end of an inflator 70. On aninner side of the valve 60 there is preferably a generally cylindricalvalve member 63 projecting therefrom. Optionally, the valve 60 alsocomprises a lip or rim 62 spaced apart from and circling the valvemember 63. Lip or rim or ring member 62 may provide added support to theinterface between the valve 60 and the volume 50 during and/or afterinflation of the volume 50.

As more clearly seen in FIG. 9, when positioned within opening 51 of thevolume 50, the thermal sealing of valve 60 to the volume 50 provides anexpandable airtight seal therebetween. When inflatable body 50 isinflated, a pressure P acts as a force keeping valve entry hole 67through opening 64 in a closed, airtight sealed manner so that no orminimal air may exit from the inflated body 50. In one embodiment, asshown in FIGS. 9-9A and 10A-10C, during inflation, the needle or head ofthe inflator 70 is extended into valve member 63 until it reaches theinner valve volume 65. As air is pumped from inflator 70 inner valvevolume 65 expands so as to concurrently open the opening 64 at the lowerend of the valve member 63. The sidewalls of the valve member 63 bulgeoutward to allow for opening 64 to expand and permit the passage of airinto the volume of inflatable body 50. In a first embodiment of valve60, as shown in FIG. 9, the valve member 63 may have a radius in therange of 4-6 millimeters (mm) and a length from valve inner partial seal66 to the valve's inner opening 64 also in the range of 4-6 mm. In asecond embodiment of valve 60, as seen in FIG. 9A, the valve member 63may again have a radius in the range of 4-6 mm and a length from valveinner partial seal 66 to the valve's inner opening 64 also in the rangeof 4-6 mm, but have an extended length from the valve entry hole 67 tothe valve inner partial seal 66. As air is pumped harder or moreforcefully, opening 64 is expanded similarly to allow the passage of agreater volume of air, as seen in FIG. 10B. Once volume 50 is filledwith the desired amount of air, needle or head of inflator 70 is removedfrom the valve entry hole 67 of the valve 60. Once removed, the pressureP of the air from within the volume 50 acts urgingly upon the sidewallsof the valve member 63 to urge close the passage from entry hole 67 tothe inner volume 65 as well as close the opening 64 with an airtightseal. Preferably, valve 60 is configured such that the opening fromvalve entry hole 67 through valve inner partial seal 66 to inner valvevolume 65 and through opening 64 into the inner region of the volume 50is maintained with airtight seal following inflation.

In an alternative embodiment of valve 60, as shown in FIG. 9B, the valvemember 63A may be configured such that the valve entry hole 67A has asubstantially wider diameter than in the prior embodiments. Such a widerentry hole 67A allows for a wider head or needle from an inflator 70A(e.g., having a diameter in the range of 0.5-0.75 inches) to be used inorder to force greater amounts of air into the inflatable body 50. Aswith the embodiments discussed above, during inflation, the needle orhead of the inflator 70A is extended into valve member 63A until itreaches a bottom end of the entry hole 67A. As air is pumped from theinflator 70A the valve member 63A expands so as to open the opening 64Aat the lower end of the valve member 63A.

The sidewalls of the valve member 63A again bulge outward to allow foropening 64A to expand and permit the passage of air from the inflator70A into the volume of inflatable body 50. In this embodiment of valve60A, as shown in FIG. 9B, the valve member 63A preferably has a radiusin the range of 4-6 mm and due to the size of valve entry hole 67A thesidewalls may have a width in the range of 2-3 mm. A length from abottom end of valve entry hole 67A to the valve's inner opening 64A isalso preferably in the range of 4-6 mm. Like the previous embodiments,as air is pumped harder or more forcefully, opening 64A is expandedsimilarly to allow the passage of a greater volume of air. Once volume50 is filled with the desired amount of air, needle or head of inflator70A is removed from the valve entry hole 67A of the valve 60A. Onceremoved, the pressure P of the air from within the volume 50 again actsupon the sidewalls of the valve member 63A to close the passage fromentry hole 67A to the opening 64A with an airtight seal. Preferably,valve 60A is configured such that the opening from valve entry hole 67Athrough opening 64A into the inner region of the volume 50 is maintainedwith airtight seal following inflation.

Referring last to FIGS. 11A-11B, shown are steps in the method ofsecuring the valve assembly 60 to the inflatable bladder 50 using athermal sealing technique in accordance with a preferred embodiment ofthe present invention. In particular, as seen in FIG. 11A, the flangeregion 61 of the valve member 63 is wrapped around an end of acylindrical heating rod 80. Optionally, heating rod 80 may have adiameter substantially similar to the diameter of the ring member 62 toaid in supporting the valve 60 during the thermal sealing process. Withflange 61 wrapped onto the end of heating rod 80, the combined valve 60and heating rod 80 are inserted into the bounded opening 51 of theinflatable body 50 as seen in FIG. 11B. The valve member 60 is thensecured with a sealing collar 90 to firmly hold the bounded wall of theopening 51 of the inflatable body 50 against the flange region 61 of thevalve member 60 between the collar 90 and the heating rod 80. During thethermal sealing flange region 61 is thermally sealed with the region ofthe bounded wall of opening 50. Because the valve member 60 ispreferably made from the same material as the inflatable body 50, thethermal seal created therebetween yields a significantly great strengththan if the materials were not the same. It will be understood, that theproposed method discuss herein, of securing a valve assembly with aninflatable bladder, may be used similarly with the alternativeembodiments in FIGS. 1-5 without departing from the scope and spirit ofthe present invention.

While a variety of plastic materials may be used with the presentinvention, as discussed herein, it has been found that preferredmaterials for use as the valve 60 and the inflatable body 50 to yieldthe greatest expandability while maintaining the integrity of the sealbetween the valve 60 and the bounded opening 51 of the inflatable body50 include plastics such as Mediprene™ 500000M (manufactured by theElasto Division of Hexpol), Dryflex™ 500040 (available through RickyEngineering Plastics Co., Ltd, Dongguan City, China), and Versaflex™CL2003X (manufactured by PolyOne Americas of Avon Lake, Ohio). Testinghas shown that, being perfectly elastic (meaning greatest elasticity,retains elasticity, durable elasticity in all directions, remainselastic after thermal bonding), Mediprene™ is the material providing thegreatest elasticity while maintaining the thermal seal. While theDryflex™ and Versaflex™ materials allow for significant elasticity andexpansion, each is not perfectly elastic and is more limited than theMediprene™. It is also noted that in one preferred embodiment theinflatable bladder is constructed from each of the above-noted preferredmaterials, particularly Mediprene™ 500000M It is noted that the furtherspecific material details of these preferred materials are available onthe internet, and via material data safety sheets and technical datasheets for each item provided by the manufacturer, and therefore thatthis material is available to one of skill in the art and isincorporated herein fully by reference.

In accordance with the present invention, a variety of bondingtechniques may be employed to secure the air valve assembly 60 to thebounded wall of opening 51 of the bladder or inflatable body 50.Examples of these bonding techniques, each of which will be discussedbelow, include thermal bonding, adhesive bonding, and the use of abonding element. The specific bonding technique utilized to secure thevalve to the bladder at least partially depends upon factors thatinclude the materials forming each of the valve and the bladder. Moreparticularly, the bonding technique utilized to secure the valve to thebladder may be selected based upon the materials forming the flange andan outer surface of the bladder.

Referring back to FIGS. 1-5, thermal bonding is one example of how valve18 being secured to bladder or bounding wall 16. In this configuration,flange 12 lays parallel to and in contact with the inner or outersurface of bladder 16. Thermal bonding may be utilized when one or bothof flange 12 and the inner/outer surface of bladder 16 incorporate thesame thermoplastic polymer (TPR) materials. Although a strength of thebond between valve 18 and bladder 16 may be sufficiently strong whenonly one of flange 12 and the inner/outer surface of bladder 16 includesa thermoplastic polymer material, the bond may exhibit greater strengthwhen both flange 12 and the inner/outer surface of bladder 16 are formedfrom compatible (i.e., readily thermal bondable) thermoplastic polymermaterials.

As utilized herein, the term “thermal bonding” or variants thereof isdefined as a securing technique between two elements that involves asoftening or melting of a thermoplastic polymer material within at leastone of the elements such that the materials of the elements are securedto each other when cooled. As examples, thermal bonding may involve (i)the melting or softening of two elements incorporating thermoplasticpolymer materials such that the thermoplastic polymer materialsintermingle with each other in an integrated and monolithic manner(e.g., diffuse across a boundary layer between the thermoplastic polymermaterials) and are secured together when cooled; (ii) the melting orsoftening of a first element incorporating a thermoplastic polymermaterial such that the thermoplastic polymer material extends into orinfiltrates the structure of a second element to secure the elementstogether when cooled; and (iii) the melting or softening of a firstelement incorporating a thermoplastic polymer material such that thethermoplastic polymer material extends into or infiltrates crevices orcavities formed in a second element to secure the elements together whencooled and becomes unitary therewith. Therefore, thermal bonding mayoccur when (i) both of flange 12 and the inner/outer surface of bladderor bounding wall 16 include thermoplastic polymer materials; or (ii)only one of flange 12 and the inner/outer surface of bladder or boundingwall 16 includes a thermoplastic polymer material. Although thermalbonding may be performed utilizing conduction as the manner in whichheat is applied to the elements, thermal bonding also includes the useof radio frequency energy (i.e., radio-frequency bonding) and highfrequency sound (i.e., sonic bonding), for example. Additionally,thermal bonding does not generally involve the use of adhesives, butinvolves directly bonding elements to each other with heat. In somesituations, however, adhesives may be utilized to supplement the thermalbond joining flange 12 and bladder or bounding wall 16.

Adhesive bonding is another example of how the valve member 18 may besecured to the bladder 16. In this configuration, the flange 12 laysparallel to the inner/outer surface of bladder or bounding wall 16 andis joined to the inner/outer surface of bladder or bounding wall 16 withan adhesive therebetween (not shown). Although flange 12 may be incontact with the inner/outer surface of bladder 16 when joined throughadhesive bonding, a thin layer of adhesive may also separate flange 12from the inner/outer surface of bladder 16. In general, adhesive bondingmay be utilized regardless of the materials forming flange 12 and theinner/outer surface of bladder 16. The chemical composition of theadhesive, however, should be selected in accordance with the particularmaterials forming flange 12 and the inner/outer surface of bladder 16.In other words, the adhesive should be selected to be capable of bondingwith both flange 12 and the inner/outer surface of bladder 16.

Still another example of how the valve may be secured to the bladder iswith a bonding element having the form of a tie layer. In thisconfiguration, flange 21 again lays parallel to the inner/outer surfaceof bladder or bounding wall 16 and is separated from the inner/outersurface of bladder 16 by a tie layer (not shown). In other words, a tielayer is positioned between flange 12 and bladder 16. Although thestructure of the tie layer may vary significantly, the tie layerpreferably has a circular and/or ring-shaped configuration. Moreover, adiameter of the tie layer is preferably greater than a diameter offlange 12. In this configuration, an outer edge of the tie layer extendsoutward and beyond an outer edge of flange 12. In addition, the tielayer may be utilized, for example, when flange 12 is formed fromvulcanized rubber and the inner/outer surface of bladder 16 is formedfrom another polymer material. The tie layer may be joined to flange 12through adhesive bonding and to bladder 16 through thermal bonding. Assuch, the tie layer may be joined to each of valve 18 and bladder 16through different bonding techniques. An advantage of using a tie layeris that it may be utilized to bond dissimilar materials in flange 12 andthe inner/outer surface of bladder 16. For example, flange 12 and theinner/outer surface of bladder 16 may be formed from materials that donot readily bond through either of thermal bonding and adhesive bonding.The material of the tie layer may, however, be selected such that (i)adhesive bonding joins the tie layer to flange 12; and (ii) thermalbonding joins the tie layer to bladder 16. Thus, the material of the tielayer may be selected to effectively join valve 18 and bladder 16.

Various factors may be considered when selecting materials for bladderor bounding wall 16. As an example, the engineering properties of thematerials (e.g., tensile strength, stretch properties, fatiguecharacteristics, dynamic modulus, and loss tangent) may be considered.The ability of the materials to be shaped into bladder elements andbonded to form seams during the manufacture of bladder or bounding wall16 may be considered. The ability of the materials to bond with valve 18through any of the bonding techniques discussed above may also beconsidered. Additionally, the ability of the materials to prevent thetransmission (e.g., diffusion, permeation) of the fluid contained bybladder or bounding wall 16 may be considered.

Suitable materials for bladder or bounding wall 16 include a variety ofthermoset and thermoplastic polymer materials. An advantage ofthermoplastic polymer materials is that they may be molded (e.g.,thermoformed) to impart the shape of each bladder element. Moreover,thermoplastic polymer materials may be thermal bonded to each other toform seams. Examples of polymer materials that may be utilized forbladder or bounding wall 16 include any of the following: polyurethane,urethane, polyester, polyester polyurethane, polyether, polyetherpolyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonatemacroglycol, and mixtures thereof. Any one of the materials noted abovemay form bladder or bounding wall 16.

In the claims, means or step-plus-function clauses are intended to coverthe structures described or suggested herein as performing the recitedfunction and not only structural equivalents but also equivalentstructures. Thus, for example, although a nail, a screw, and a bolt maynot be structural equivalents in that a nail relies on friction betweena wooden part and a cylindrical surface, a screw's helical surfacepositively engages the wooden part, and a bolt's head and nut compressopposite sides of a wooden part, in the environment of fastening woodenparts, a nail, a screw, and a bolt may be readily understood by thoseskilled in the art as equivalent structures.

Having described at least one of the preferred embodiments of thepresent invention with reference to the accompanying drawings, it is tobe understood that such embodiments are merely exemplary and that theinvention is not limited to those precise embodiments, and that variouschanges, modifications, and adaptations may be effected therein by oneskilled in the art without departing from the scope or spirit of theinvention as defined in the appended claims. The scope of the invention,therefore, shall be defined solely by the following claims. Further, itwill be apparent to those of skill in the art that numerous changes maybe made in such details without departing from the spirit and theprinciples of the invention. It should be appreciated that the presentinvention is capable of being embodied in other forms without departingfrom its essential characteristics.

What is claimed is:
 1. An air valve assembly for an inflatable body, said air valve assembly comprising: a generally flexible body member having an inner and an outer surface, and a generally cylindraceous projection extending from said inner surface of said body member; wherein said outer surface is substantially smooth, wherein said projection is generally positioned proximate a central region of the central region of said body member, and has a self sealing opening extending longitudinally therethrough for the passage of air from said outer surface to said inner surface upon inflation by an external inflating device positioned within said projection during a use thereof, wherein a generally radially region of said of said body member distal said cylindraceous projection is thermally bonded to a surface of said inflatable body proximate an opening in said inflatable body; wherein at least one of said body member, said inflatable body, and both said body member and said inflatable body is made from a material selected from the group consisting of thermoplastic elastomer (TPE), thermoplastic rubber (TPR), polyester-based polyurethane, polyether-based polyurethane, polyvinyls, polyesters, polyethers, rubber, latex, nylon, vinyl, polychioroprene, synthetic fabric, synthetic rubber, natural rubber, Mediprene®, Dryflex®, Dynalloy® and Versaflex®.
 2. The air valve assembly according to claim 1, wherein a flange region of said body member is affixed to said inflatable body using a bonding technique selected from the group consisting of adhesive bonding, thermal bonding, element or tie bonding, and co-bonding.
 3. The air valve assembly according to claim 2, wherein a region of said body member extending radially outward from said ring member the region of said body member that is thermally bonded to the surface of said inflatable body.
 4. A method of manufacturing an inflatable body said method comprising the steps of: providing an air valve assembly according to claim 1, for said inflatable body securing an outer flange region of said valve assembly to an outer circumference of a cylindrical heating rod; inserting said heating rod with said valve assembly into a bounding wall of said inflatable body, said valve member assembly and said bounding wall being substantially formed from said thermoplastic rubber material; securing said valve member assembly to said bounding wall with a sealing collar, said sealing collar being generally cylindrical so as to fit around said outer circumference of said heating rod; and sealing using said heating rod to heat said valve member assembly and said bounding wall so as to seal a surface of said bounding wall to a surface of said valve member assembly.
 5. The method according to claim 4, further including the step of: co-bonding an o-ring within said valve member assembly, said o-ring being substantially formed from a thermoplastic rubber material.
 6. The method according to claim 5, wherein: said thermoplastic rubber material of said o-ring is of a higher density than said thermoplastic rubber material of said valve member assembly.
 7. The method according to claim 6 wherein: said peripheral flange is secured to an exterior circumference of a first end of said cylindrical heating rod.
 8. The method according to claim 7, wherein: said peripheral flange is secured to an exterior circumference of a first end of said cylindrical heating rod using said sealing collar.
 9. The method according to claim 8, wherein: said heating rod has a diameter substantially the same as a diameter of a ring member protruding from an inner surface of said valve member assembly. 